AGMA 919-1-A14-2014 Condition Monitoring and Diagnostics of Gear Units and Open Gears Part 1 - Basics.pdf

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1、AGMA919-1-A14AGMA 919-1-A14 AGMA Information Sheet Condition Monitoring and Diagnostics of Gear Units and Open Gears: Part 1 - Basics AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 919-1-A14 American Gear Manufacturers Association Approved July 2014 ABSTRACT Condition Monitoring and Diagnostics of Gea

2、r Units and Open Gears: Part 1 - Basics AGMA 919-1-A14 CAUTION NOTICE: AGMA technical publications are subject to constant improvement, revision or withdrawal as dictated by experience. Any person who refers to any AGMA Technical Publication should be sure that the publication is the latest availabl

3、e from the Association on the subject matter. Tables or other self-supporting sections may be referenced. Citations should read: See AGMA 919-1-A14, Condition Monitoring and Diagnostics of Gear Units and Open Gears: Part 1 - Basics, published by the American Gear Manufacturers Association, 1001 N. F

4、airfax Street, Suite 500, Alexandria, Virginia 22314, http:/www.agma.org. This information sheet provides basic overviews of key approaches to establishing a condition monitoring and diagnostics program for open gearing and enclosed gear units. Published by American Gear Manufacturers Association 10

5、01 N. Fairfax Street, Suite 500, Alexandria, Virginia 22314 Copyright 2014 by American Gear Manufacturers Association All rights reserved. No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without prior written permission of the publisher. Pri

6、nted in the United States of America ISBN: 978-1-61481-087-2 AGMA 2014 All rights reserved ii AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 919-1-A14 Contents Foreword iv 1 Scope . 1 2 Normative references. 1 3 Terminology and nomenclature . 2 3.1 Symbols. 2 4 Condition monitoring 3 4.1 Continuous mo

7、nitoring 3 4.2 Translational vibration . 4 4.2.1 General 4 4.2.2 Transducers for translational vibration 4 4.2.3 Installation effects . 5 4.2.4 Translational vibration guidelines 5 4.2.5 Fundamentals of gear unit diagnostics . 6 4.3 Temperature 6 4.3.1 General 7 4.3.2 Measured temperatures 7 4.3.3 E

8、xternal coolers. 8 4.3.4 Diagnostics 8 4.3.5 Open gearing temperature gradient 9 4.4 Lubrication. 9 4.4.1 Lubricant inspection 9 4.4.2 Open gearing. 10 4.5 Load 10 4.5.1 Load monitoring. 10 4.6 Typical NDE inspection techniques for gearing 11 4.6.1 Visual inspection . 11 4.6.2 Gear accuracy inspecti

9、on 12 4.6.3 Magnetic particle and liquid penetrant inspection . 12 4.6.4 Ultrasonic inspection, UT 13 4.6.5 Ultrasonic phased array 13 4.6.6 Eddy current 14 4.6.7 Eddy current array, ECA . 14 Tables Table 1 - Symbols . 2 Table 2 - Translational vibration guidelines 6 Figures Figure 1 - Vibration tra

10、nsducer mounting techniques . 5 Figure 2 - Visual examination showing localized pitting due to misalignment between geared elements . 11 Figure 3 - Cracks visible using magnetic particle inspection 12 Figure 4 - Crack visible using liquid penetrant inspection. 13 Figure 5 - Different inspection area

11、s covered by ECA and UT. 13 Figure 6 - Gear tooth crack . 14 Figure 7 - C-scan image using eddy current array of the tooth shown in Figure 6. 14 AGMA 2014 All rights reserved iii AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 919-1-A14 Foreword The foreword, footnotes and annexes, if any, in this docu

12、ment are provided for informational purposes only and are not to be construed as a part of AGMA Information Sheet, 919-1-A14, Condition Monitoring and Diagnostics of Gear Units and Open Gears: Part 1 - Basics. The AGMA Sound and Vibration committee developed this information sheet to offer basic pri

13、nciples for a condition monitoring program. Part two of this information sheet will provide additional details of the concepts discussed in this document. The first draft of AGMA 919-1-A14 was made in August, 2013. It was approved by the AGMA membership on April 25, 2014. Suggestions for improvement

14、 of this standard will be welcome. They may be submitted to techagma.org. AGMA 2014 All rights reserved iv AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 919-1-A14 PERSONNEL of the AGMA Sound and Vibration Committee Chairman: Darwin D. Behlke Twin Disc, Incorporated Vice Chairman: Richard A. Schunck R

15、exnord Gear Group ACTIVE MEMBERS R.W. Hankes . A-C Equipment Services F. Porzio SKF Industrie S.p.A. C. Robertson Lufkin Industries S. Rogan . Artec Machine Systems T. Shumka . Global Inspections - NDT, Inc. R. White John Deere B.K. Wilson Romax Technology Inc. AGMA 2014 All rights reserved v AMERIC

16、AN GEAR MANUFACTURERS ASSOCIATION AGMA 919-1-A14 American National Standard - Condition Monitoring and Diagnostics of Gear Units and Open Gears: Part 1 - Basics 1 Scope This information sheet provides basic overviews of key approaches to establishing a condition monitoring and diagnostics program fo

17、r open gearing and enclosed gear units. This information sheet attempts to inform the reader of the common techniques used and parameters measured for condition monitoring of a gear unit allowing the reader to build a program based on individual needs. Due to the wide variety of gearing applications

18、 some approaches discussed may not be appropriate in all situations. This information sheet is intended for use by someone with a technical background. 2 Normative references The following standards contain provisions which, through reference in this text, constitute provisions of this information s

19、heet. At the time of publication, the editions indicated were valid. All publications are subject to revision, and the users of this information sheet are encouraged to investigate the possibility of applying the most recent editions of the standards indicated below. ANSI/AGMA 1010, Appearance of Ge

20、ar Teeth - Terminology of Wear and Failure ANSI/AGMA 2015-1, Accuracy Classification System - Tangential Measurements for Cylindrical Gears ANSI/AGMA 6000, Specification for Measurement of Linear Vibration on Gear Units ANSI/AGMA 6014, Gear Power Rating for Cylindrical Shell and Trunnion Supported E

21、quipment ANSI/AGMA 9005, Industrial Gear Lubrication ASTM A388/A388M-11, Standard Practice for Ultrasonic Examination of Steel Forgings ASTM A609-12, Standard Practice for Castings, Carbon, Low-Alloy, and Martensitic Stainless Steel, Ultrasonic Examination Thereof ASTM E165-12, Standard Practice for

22、 Liquid Penetrant Examination for General Industry ASTM E709-08, Standard Guide for Magnetic Particle Testing ASTM E1444-12, Standard Practice for Magnetic Particle Testing ASTM E2491-13, Standard Guide for Evaluating Performance Characteristics of Phased-Array Ultrasonic Testing Instruments and Sys

23、tems ASTM E2700-09, Standard Practice for Contact Ultrasonic Testing of Welds Using Phased Arrays ASTM E2905/E2905M-12, Standard Practice for Examination of Mill and Kiln Girth Gear Teeth - Electromagnetic Methods ISO 10816-1, Mechanical vibration - Evaluation of machine vibration by measurements on

24、 non-rotating parts - Part 1: General guidelines ISO 10816-3, Mechanical vibration - Evaluation of machine vibration by measurements on non-rotating parts - Part 3: Industrial machines with nominal power above 15 kW and nominal speeds between 120 r/min and 15 000 r/min when measured in situ. ISO 108

25、16-6, Mechanical vibration - Evaluation of machine vibration by measurements on non-rotating parts - Part 6: Reciprocating machines with power ratings above 100 kW AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 919-1-A14 3 Terminology and nomenclature alarm. operational signal or message designed to n

26、otify personnel when a selected anomaly, or a logical combination of anomalies, requiring corrective actions is encountered. NOTE: An alarm is a more severe anomaly zone than an alert and should be identified with a red indicator. availability. probability that a machine will, when used under specif

27、ied conditions, operate satisfactorily and effectively. catastrophic failure. sudden, unexpected failure of a gear unit resulting in considerable damage to the machine and/or associated machines or components. condition monitoring. detection and collection of information and data that indicate the s

28、tate of a gear unit. failure. termination of the ability of an item to perform a required function. NOTE: Failure is an event as distinguished from fault, which is a state. fault. condition of a component that occurs when one of its components or assemblies degrades or exhibits abnormal behavior, wh

29、ich may lead to the failure of the gear unit NOTE 1: A fault may be the result of a failure, but can exist without a failure. NOTE 2: Planned actions or lack of external resources are not a fault. fault frequency. dynamic transducer frequency generated by a specific fault. frequency domain. display

30、of frequencies present in a sample of a waveform. gear mesh frequency. Gear mesh frequency is the frequency at which gear teeth enter their mesh. gear unit. mechanical system including open gearing and enclosed gear units that transfer motion and torque from driving to driven equipment. NOTE: A gear

31、 unit may sometimes be referred to as equipment. predictive maintenance. maintenance as the result of prediction of impending failure. steady-state. a condition in which the speed, load and temperature exhibit negligible change over the measurement period. time domain. display of the behavior of a s

32、ystem during a specific period of time. thermal effects. change in the dimensions of a component caused by a change in temperature. trending. analysis of a performance parameter over time. 3.1 Symbols The symbols used in this standard are shown in Table 1. NOTE: The symbols and terminology used in t

33、his standard may differ from other AGMA standards. The user should not assume that familiar symbols can be used without careful study of Table 1. Table 1 - Symbols Symbols Description Units First used cm P Q Tin Tout Lubricant specific heat Power dissipated through cooler Lubricant flow rate Cooler

34、inlet lubricant temperature Cooler outlet lubricant temperature Lubricant density J/kg-C kW liter/sec C C kg/liter 4.2.3 4.2.3 4.2.3 4.2.3 4.2.3 4.2.3 AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 919-1-A14 4 Condition monitoring Condition monitoring of critical machinery is a well-established practi

35、ce in many industries, providing continuous or periodic monitoring of relevant performance parameters. Analysis of the performance parameter behavior over time, often referred to as trending, may show a pattern indicative of developing issues. The objective is to identify and closely monitor the dev

36、eloping issue before it negatively affects the performance of the critical machinery due to unscheduled downtime or a catastrophic failure. Monitoring allows the machinery operators and maintenance personnel to schedule the necessary maintenance activities, thereby increasing machinery productivity,

37、 saving money and time. To gain a fundamental understanding of the evolving operational and performance behavior of a gear unit over a specified time period, a robust data collection process must be firmly established. To be effectively implemented, a condition monitoring program must have the suppo

38、rt of not only the maintenance, operational and engineering departments, but also executive management. For example, this may include accommodating rigorous testing requirements, such as operating at specific loads and speeds during data collection for comparison and trending purposes. Critical elem

39、ents of a condition monitoring process include, but are not limited to, detailed provisions for the following: - establishment of baseline; - consistent measurements and samples; steady state/repeatable operating state; - operating temperature; - environmental conditions such as time of day, humidit

40、y, and ambient temperature; - equipment load and speed; consistent data acquisition equipment/operator; consistent transducer locations. It is good practice to take measurements at the same operating conditions, using the same equipment, under the same environmental conditions, operated by the same

41、people to obtain repeatable results. If the same personnel are not available, ensure that the same technique and procedures are being followed to record the readings. As data is collected over time, the impact of differing conditions can be determined allowing ranges to be established on applicable

42、parameters. The sensitivity of each measurement parameter to various operating conditions must be individually determined. Basic machine condition monitoring performance parameters may include: - translational vibration; - temperature; - lubricant condition; - load; - speed. A second strategy for ge

43、ar unit monitoring is non-destructive testing, NDT. This monitoring is performed when the gear unit is not in operation. Alignment problems, micropitting and cracks, are examples of distress that are difficult to detect while the gear unit is in operation, but can be detected by NDT methods. 4.1 Con

44、tinuous monitoring When establishing a robust condition monitoring program, an organization must determine which machinery is critical to operations, thereby requiring an investment in time and resources to properly maintain it. Once a decision has been made regarding the critical machinery to be in

45、cluded, the responsible party must determine how often data will be collected from each piece of machinery (periodically), such as monthly, weekly, daily, or for highly critical machinery, continuously. Periodic monitoring usually constitutes the manual collection of data, although the instrumentati

46、on itself may or may not be permanently installed. Continuous monitoring requires permanently installed instrumentation, as well as a means for evaluating the data as quickly as possible in order to determine the real-time health of the machinery. Continuous monitoring of an enclosed gear drive unit

47、 may encompass all or some of the following parameters: - lubricant supply pressure; - temperatures; - housing vibration; AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 919-1-A14 - shaft vibration; - acoustic emissions; - lubricant flow; - load; - speed. 4.2 Translational vibration This clause will pr

48、esent traditional approaches to the use and analysis of translational vibration, often referred to as “linear” vibration. 4.2.1 General Operational excitations from gears, bearings, shafts and other rotating components result in translational vibration of both the shafts and the housing structure. A

49、n effective indicator of gear unit condition is the trend of the vibration of a rigid housing section, e.g., a bearing boss or block. A typical approach is to measure translational vibration in three orthogonal directions (horizontal, vertical, axial) at both input and output bearing locations. Intermediate shaft bearing locations may also be monitored in some gear unit configurations. When rolling element bearings are used, the vibration of the lower shaft orders, refer